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Basic Elements of Explosion Basic Elements of Explosion Protection in the EU Legislative Protection in the EU Legislative
ContextContext
Dr.-Ing. Uwe KlausmeyerDr.-Ing. Uwe KlausmeyerPhysikalisch-Technische BundesanstaltPhysikalisch-Technische Bundesanstalt
Braunschweig, GermanyBraunschweig, Germany
ATEX Symposium22 – 24 Eylül 2011, Ankara, Türkiye
The ATEX RegulationThe ATEX Regulation
EU Directives of the „New Approach“ Legislative EU Directives of the „New Approach“ Legislative Framework, consisting of:Framework, consisting of:- 94/9/EC (trade of equipment, ESRs)- 94/9/EC (trade of equipment, ESRs)- 1999/92/EC (safety of workplace)- 1999/92/EC (safety of workplace)
Accident in Oppau, GermanyAccident in Oppau, Germany
Accident in Buncefield‚UK, 2005Accident in Buncefield‚UK, 2005
Buncefield, 2005Buncefield, 2005
Buncefield, 2005Buncefield, 2005
Accident at INEOS near Cologne, GermanyAccident at INEOS near Cologne, Germany17th of March, 200817th of March, 2008
Pipeline ofEthyleneis burning
Has set fire to amethylacetate tank
Explosion Explosion protectionprotection
Oxy
gen
Combustible
Ignition sourceProper Compostition
Avoid concurrence:Avoid concurrence:- Oxygen (air)!!! Inertization
- Ignition source!!! Elimination
- Combustibles (gas, vapour, dust)!!! Ventilation
- Convection
- Buoyancy
SpreadSpread of of gasesgases
Lighter than air
Heavier than air
Spread of liquids, leakagesSpread of liquids, leakages
Gas
Gasoline
Combustible liquidsCombustible liquids
5 ml gasoline is enough to produce 200 l of explosive atmosphere, which can destroy a barrel!
Formation of highly flammable vapour/ air mixture can occur when handling with even small amounts of break cleaners!
Spread of combustible dustsSpread of combustible dusts
Dust layers with a thickness of 1 mm can be enough to produce explosive atmospheres!
Critical concentration of Flammable Critical concentration of Flammable substancessubstances (safety characteristics) (safety characteristics)
Influence of concentrationInfluence of concentration
Ignition sources – EN 1127-1Ignition sources – EN 1127-1
Ignition of an explosive atmosphere can be caused by various sources:• hot surfaces• flames and hot gases• mechanically generated sparks• electrical installations• equalizing currents, cathodic corrosion protection• static electricity• lightning• electromagnetic waves (high-frequency)• optical radiation• ionising radiation• ultrasonics• adiabatic compression and shock waves• exothermal reactions
Different types of protections (safety Different types of protections (safety concepts) offered by EN/IEC standardsconcepts) offered by EN/IEC standards
Gases/Vapours Dusts
Type of protection Symbol Electricalequipment
Non-electricalequipment
Electricalequipment
Flameproof enclosure d ● ● -
Protection by enclosure tD - - ●
Enclosed break device nC ● - -
Non-incendive component nC ● - -
Pressurized apparatus p ● ● ●
Powder filling q ● - ●
Oil immersion o/k ● ● -
Increased safety e ● - -
Non-sparking nA ● - -
Constructive safety c - ● -
Encapsulation m ● - ●
Hermetically sealed device nC ● - -
Sealed/encapsulated device nC ● - -
Intrinsic safety i ● - ●
Restricted breathing enclosure nR/fr ● ● ●
Protection by control of ignition sources b - ● -
Flameproof enclosure “d”, to mitigate Flameproof enclosure “d”, to mitigate an explosion hazardan explosion hazard
Explosive gasmixture
Ignition devicepressure transducer
Special preparation:
•Max tolerances at all gaps
•Without gaskets and grease
44
1
12
33
3
5
4
4
5
6
Ignition hazards of a complex apparatus:Ignition hazards of a complex apparatus:a fork lift (electrical motor or combustion a fork lift (electrical motor or combustion
engine)engine)
Electrical apparatus
•Motor „d“, „e“•control device „d“, „e“, „i“•accumulator „e“•plug and socket „d“•lighting fixture and
control lights „d“, „e“
1
Electrical installation2• IEC/EN 60079-14
Mechanical apparatus3
•Brakes and oil hydraulic system/components
Sparks caused by metallic parts5• Coating with brass, bronze and
stainless steel
Electrostatic charge• Conductable wheels• conductable seat material• conductable housing• grounding against electrostatic charge
4
Temperature control6•Motor control device•motor•hydraulic oil/system
Engine7
7
The ATEX RegimeThe ATEX Regime
• Free Trade Directive 94/9/EC in the Internal EU Market (Essential Health and Safety Requirements – ESRs, obligations of the manufacturer)
• Worker protection (Social) Directive 1999/92/EC (obligations of the end user)
• ATEX Standing Committee
• ATEX Notified Bodies
• ATEX Consultant, CENELEC, CEN, Presumption of Conformity with ESRs
What‘s about this „mark“????What‘s about this „mark“????
Chinese Export, Confusion Everywhere ;-))))
1. Conformité Européenne (FR)2. Legal mark, NOT a quality mark like TSE, VDE, UL… IECEx3. Affixed by a manufacturer on his own responsibilty4. may be based on an EC Type Examination Certificate by an independent ATEX Notified body, in the ATEX field only for Zone 0 and Zone 1 classified areas5. installation and instruction manual!!!!! installation and instruction manual!!!!!
11.10.2001
(Low Voltage Directive 73/23/EEC)Machinery Directive 98/37/ECATEX (Explosion-proof equipment) 94/9/ECEMC Directive 89/336/EECPressure Equipment Directive 97/23/ECR&TTE-Directive 1999/5/ECToys Directive 88/378/EECPersonal Protective Equipment Directive 89/686/EECConstruction Products Directive 89/106/EECMedical Devices Directive 93/42/EEC(CE-Kennzeichnungs-Richtlinie 93/68/EEC)
Important directives of the New ApproachImportant directives of the New Approach
Relation of ATEX, CEN/CENELEC, ISO Relation of ATEX, CEN/CENELEC, ISO and IEC/IECExand IEC/IECEx
New Practice of many ATEX Notified Bodies (IECEx ExCB) New Practice of many ATEX Notified Bodies (IECEx ExCB) is to use the elements of IECEx (ExTRs, QAR) to issue a EC is to use the elements of IECEx (ExTRs, QAR) to issue a EC Type Examination Ccertificate and the QA NotificationType Examination Ccertificate and the QA Notification
ATEX Notified Bodies - Nando
IEC vs. CEN/CENELECIEC vs. CEN/CENELEC
• Dresden/Vienna Agreement on Parallel Voting of documents, stand still agreement CLC/IEC
• EN 60079-0 (former edition EN 50014 - EEx) is equivalent to IEC 60079-0 (Ex),EN/IEC 60079-1 „d“, -2 „p“, -5 „q“, -6 „o“,-7 „e“, -11 „i“, ….. , -18 „m“, -26 „Zone 0“…., -34 „QM Production“, -36, -37 (mech.)
• Plant operation: EN/IEC 60079-10-1/-2, EN/IEC 60079-14, -17, -19
Safety concepts for equipment – older Safety concepts for equipment – older versions of the standardsversions of the standards
Selection and installation of equipment in accordance to EN/IEC 60079-14
Zone Equipment category
(Directive 94/9/EG)
Safety level
0 /20
II 1 G/D
Even in the event of infrequent malfunctions
1/21
II 1 G/D oder II 2 G/D
In the event of expected malfunctions
2/22
II 1 G/D oder
II 2 G/D oder II 3 G/D
Normal operation
Temperatur Class:
Explosion Group
II A Methan, Benzine, Methanol
II B Schwefelwasserstoff II C Wasserstoff, Acetylen
Maximum surface temperature
Classification of equipment inaccordance to EN/IEC 60079-0
Explosion characteristics Methane Biogas 70 % CH4
30 % CO2
Petrol Propan
Explosion limits /air [Vol.- %] 4,4 - 17 4,4 - 14 0,6 - 8 1,7- 10,9
Ingition Temperature [0C] 595 220 - 260 450
Relative density (air = 1) 0,55 0,85 ca. 3,2 (gas) 1,55
Flashpoint [0C] < - 20 - 104
Temperaturclass T 1 T 1 T 3 T 3
Explosion group II A II A II A II A
Max. Ex.- pressure [bar] 8,1 8,5 9,4
Hazardous substance andHazardous substance andsafety characteristics (EN/IEC 60079-20)safety characteristics (EN/IEC 60079-20)
Examples of 94/9-equipment with Examples of 94/9-equipment with EC Declaration of ConformityEC Declaration of Conformity
To be installed in accordance with IEC 60079-14
Classification of equipmentClassification of equipment
Minimum duties of the manufacturerMinimum duties of the manufacturer
Electrical equipment
• Category 1/M1:- EC Type Examination Cert.- QA Notification/Annex IV
• Category 2/M2:- EC Type Examination Cert.- QA Notification/Annex VII
• Category 3:- self declaration of conformity, ATEX Notified Body not required
Mechanical equipment
• Category 1/M1:- EC Type Examination Cert.- QA Notification/Annex IV
• Category 2/M2:- self declaration of conformity- Deposit of product documentation at an ATEX Notified Body
• Category 3:- self declaration of conformity, ATEX Notified Body not required
Way to the CE markingWay to the CE marking
CE – conformity marking# andEC – declaration of conformity by the manufacturer(Annex X)
category 1, M1equipment,protective systems
category 2, M2electrical equipment,combustion engines
category 2, M2non-electricalequipment
category 3equipment
Unit verification(Annex IX)
Productionqualityassurance(Annex IV) orProductverification(Annex V)
Productqualityassurance(Annex VII)
orConformityto type(Annex VI)
ECtype-examinationcertificate(Annex III)
ECtype-examinationcertificate(Annex III)
Deposit ofdocumentation(Article 8, 1b ii)
Internalcontrol ofproduction(Annex VIII)
Internalcontrol ofproduction(Annex VIII)
all categoriesequipment,protective systems
Notified Body
ManufacturerCategory accordingarticle 8
#: not for components according Article 8, 3
EC Declarationof Conformity
01.01.2010
EC Declarationof Conformity
01.01.2010
Risk assessment acc. ATEX Directive 1999/92
•Probability and duration of a significant amount of explosive gas or dust atmosphere (Zone classification in acc. to EN/IEC 60079-10-1, -2)
•Probability and energy of ignition source
•scale of damages which might occur
The employer hasto conduct an
ignition risk assessment:
EU-Directive 1999/92/EGEU-Directive 1999/92/EGand IEC 60079-10-1and IEC 60079-10-1
Zone 0 A place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the form of gas, vapour or mist is present continuously or for long periods or frequently.
Zone 1A place in which an explosive atmosphere consisting of a mixture with air or flammable substances in the form of gas, vapour or mist is likely to occur in normal operation occasionally.
Zone 2A place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the form of gas, vapour or mist is not likely to occur in normal operation but, if it does occur, will persist for a short period only.
Directive 1999/92/EGDirective 1999/92/EGand IEC 60079-10-2and IEC 60079-10-2
Zone 20A place in which an explosive atmosphere in the form of a cloud of combustable dust in air is present continously, or for long periods or frequently.
Zone 21A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation occasionally.
Zone 22A place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if itdoes occur, will persist for a short period only.
Examples for zoning hazardous areas –Examples for zoning hazardous areas –example of IEC 60079-10example of IEC 60079-10
Stirrer
Examples of 94/9-equipment with Examples of 94/9-equipment with EC Declaration of ConformityEC Declaration of Conformity
CE – EU Dir. 94/9 marked equipment is required by the user‘s directive 1999/92
Explosion protection document: description of the plant, the process, the activities and flammable material quantities
material data
results of the explosion risk assessment
Explosion protection measures
Organizational measures (training staff, …)
Directive 1999/92/EGDirective 1999/92/EG(1) Documentation(1) Documentation
Get assistance by NAMUR.de andNAMUR recommendation xyz
MaintenanceIEC 60079-17and -19
• Ensure expertise of the personell
• Training and experience must be ensured
• Prevent occurence of hazardous atmophere
• install a fire monitor if necessary
• Making sure before restarting that the explosion protection measures required for normal operation have been reactived
• clean dust deposits from installed products
Directive 1999/92/EGDirective 1999/92/EG(2) Maintenance(2) Maintenance
The ATEX Standing CommitteeThe ATEX Standing Committee
• Representatives coming from Ministries of the EU Member States, Industry Associations, ExNB Group, Standardization Bodies CENELEC and CEN, ATEX Consultant, …. the Stakeholders
• Interpretation of the Directives 94/9 and 1999/92
• Interface to other Directives, e.g. to the Machinery Directive
• Meeting once a year in Brussels
ATEX Notified Body groupATEX Notified Body group
The ATEX Notified Bodies– More than 60 ATEX Notified Bodies with similar scopes– but it is a national notificationnotification, not an accreditation in
acc. with ISO/IEC standards– requirements for notification see annex XI of the 94/9– general experience: no chance outside EU with such a
notification, ISO/IEC 17025 and ISO Guide 65 are to be applied by internationally recognized ILAC/IAF accreditation bodies like TÜRKAK
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